Flavor pouch

ABSTRACT

A flavor pouch includes a porous covering that encloses a carrier having a flavorant. The carrier may be solid or particulate. Flavorants may be one or more of tea, coffee, rose hips, honey, royal jelly, fruit extracts, mint, sweeteners, ginger, pepper extract, exotic flavors, ethnic flavors and the like. Where the carrier comprises a plurality of beads, the beads may have randomly dissolvable encapsulation to extend the time duration of flavor release. To use the flavor pouch, it is placed in the mouth and masticated or exposed to saliva to thereby release the flavorant.

RELATED APPLICATIONS

This application is a Continuation Application of U.S. application Ser.No. 11/601,622, entitled FLAVOR POUCH and filed on Nov. 20, 2006, whichclaims priority under 35 U.S.C. §119 to U.S. Provisional Application No.60/738,034 entitled FLAVOR POUCH and filed on Nov. 21, 2005, the entirecontent of which is hereby incorporated by reference.

FIELD OF THE INVENTION

This disclosure concerns a flavor pouch for oral delivery of one or moreselected flavorants.

SUMMARY

Broadly, the flavor pouch of this disclosure comprises an externalwrapper that encloses a flavor source. Preferably the pouch is sized tocomfortably be received in a human mouth. In addition, the pouch may besized so that it can be moved around inside a human mouth, while notmaterially interfering with speech or oral breathing.

The external wrapper preferably comprises a membrane that issufficiently porous to allow transport through the membrane of flavorfrom the source. A preferred configuration of the pouch is generallycrescent-shaped. Such a crescent shape facilitates manufacture andreduces the amount of peripheral edge sealing that would otherwise beneeded. The external wrapper membrane is preferably resistant todeterioration in the presence of saliva and bacteria.

The flavor source may comprise a strip of material having the desiredflavor characteristics. Those flavor characteristics may be natural,synthetic, artificial or combinations thereof. Moreover, those flavorcharacteristics may be (i) applied to the surface of the strip, (ii)integral with the material of the strip, or (iii) additives in the bodyof the strip material.

Other flavor sources may be beads, with or without solubleencapsulation. Encapsulation may provide a time-release function so thatthe flavorant is dispensed over a longer time period than wouldotherwise occur. Alternatively, the flavor source may also be a solid ora highly viscous fluid. Furthermore, the flavor source may be a matrix,either natural or synthetic, capable of holding flavorant materials orcompounds.

Preferred flavorants for use in the pouch include, without limitation,both natural and artificial flavor compounds. Preferred flavors arepreferably adult flavors that are neither sweet nor sour. Preferredadult flavors for use are, again without limitation, tea, rose hips,honey, royal jelly, fruit extracts, vitamins, coffee, mint, spices suchas ginger, pepper extract, exotic fruits, exotic vegetables,international, and ethnic flavors.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a top view of a flavor pouch.

FIG. 2 is cross-sectional view of the flavor pouch taken along the line2-2 of FIG. 1.

FIG. 3 is a cross-sectional view of a second embodiment of the flavorpouch of FIG. 1 with a different flavor source.

FIG. 4 is a cross-sectional view of a third embodiment of the flavorpouch of FIG. 1 with still another flavor source.

FIG. 5 is a plan view of a blank for making the flavor pouch.

FIG. 6 is a plan view of the blank with a filling in place.

FIG. 7 is a plan view of the folded blank.

FIG. 8 is a plan view showing the location of a thermal weld.

DETAILED DESCRIPTION

Turning now to FIG. 1, a flavor pouch 20 is depicted according to oneembodiment of this disclosure. Overall dimensions of the pouch 20 areselected so that it can be comfortably received in a human oral cavity.Typically, the pouch 20 is sized so as to comfortably fit between theconsumer's cheek and gum in the jaw area. By way of example, and withoutlimitation, the major dimension of the pouch 20 may be in the range ofabout 0.6 to about 1.2 inches while the transverse dimension of thepouch may be in the range of about 0.35 to about 0.75 inches. With suchdimensions, the pouch 20 can be comfortably positioned in the oralcavity or on the tongue. Where the pouch 20 is designed to be retainedbetween the cheek and the gums of the oral cavity, the proportions ofthe pouch may be smaller. With dimensions in the ranges set out above,the pouch 20 can be retained in the oral cavity without any substantialinterference with speech or breathing. Such a pouch 20 can also bemaneuvered or manipulated by the tongue to move the pouch around in theoral cavity.

In the illustrated embodiment, the pouch 20 is shaped generally like asegment of a circle with rounded or filleted corners. Preferably, thepouch 20 is substantially free of oral cavity irritant, which, as usedherein, means that the shape, configuration, and position of the pouch20 do not irritate oral tissues (e.g, gums). Furthermore, “substantial”and “substantially free” as used in connection with oral cavity irritantmean that the shape, configuration, and position of the pouch 20 doesnot irritate oral tissues (e.g, gums) in a time frame having the sameorder of magnitude as a typical length of time during which the pouch 20is enjoyed by a user. Generally, sharp corners are preferably avoided assharp corners may lead to oral discomfort. In addition to sharp corners,sealed edge potions (seams) along the consumer's gum base may lead tooral discomfort. Accordingly, when inserted into the mouth and alignedto the consumer's gum base, the presently disclosed pouch 20 that issubstantially free of oral cavity irritant does not have any sealed edgepotion or sharp corner along the consumer's gum base. While theillustrated embodiment of the pouch 20 is generally a circular segment,many other configurations are within the contemplation of thisdisclosure. For example, other shapes may also be selected for the pouch20 including, for example, elliptical, oblong, polygonal with roundedcorners or without rounded corners when the number of sides issufficiently large that the non-rounded corners do not create asubstantial irritant.

The pouch 20 preferably includes a cover material 22 that is suitablefor oral use and which is not soluble in saliva. More particularly, itis preferred that the cover material 22 of the pouch 20 maintainsufficient structural integrity during the time period that the pouch 20is used that the cover material 22 will retain flavorant carriermaterial contained therein. The cover material 22 may be fabricated fromnatural material, synthetic material, or a combination of natural andsynthetic materials. Preferably, the cover material 22 is selected so asto be tasteless and may comprise a woven or non-woven web. Nevertheless,it is further contemplated that the cover material 22 may interact withthe flavorant and/or its carrier in the presence of saliva to generate amore complex flavor.

Where the pouch 20 has a crescent shape, the cover material 22 may befolded on itself so that it has an integral edge portion 24 andoverlapping edge portions 26. The overlapping edge portions 26 aresealed together. Preferably, that sealing function is accomplished by anadhesive or by mutual sealing the overlapping edge portions 26. Suchmutual sealing may be thermal or sonic. Where the pouch 20 has adifferent external contour, the cover material 22 for the pouch 20 maybe in two overlapping pieces. If desired, the crescent-shaped pouch 20may also be fabricated from two overlapping pieces. Where overlappingpieces are used, the peripheral edge portions of the pieces arepreferably sealed together, as described above.

While pouches have traditionally used cellulose fiber as the covermaterial, e.g., tea bags, alternative pouch materials may also beadvantageously used as the covering material disclosed herein.Alternative cover materials with a neutral or pleasant taste or odorpreferably have the properties of stain resistance, color, waterpermeability and/or porosity, and/or water insolubility.

Additionally, the cover materials used for the pouch materials can beprovided with predetermined levels for basis weight and/or wet strengthto minimize breakage of the pouch cover material during storage and use.For example, pouch cover materials may have a basis weight of about 5 toabout 25 grams/square meter (g/m²), such as 5-10, 10-15, 15-20, or 20-25g/m², and/or a wet tensile cross-direction (CD) strength of about 15 toabout 75 N/m (Newtons/meter), such as 15-30, 30-45, 45-60, or 60-75 N/m.The basis weight and/or tensile strength are preferably sufficient formaintaining integrity of the pouch 20 so that any internal material willbe retained therein. One exemplary pouch cover material has a basisweight of about 16.5 g/m² and a wet tensile CD strength of 68 N/m.

In an exemplary embodiment, a water-permeable, water-insoluble, porous,stain-resistant polymer membrane can be used as the pouch cover materialto allow flavor from a barrier material to permeate through the pouchcover material thereby minimizing absorption or trapping of the flavorwithin the pouch cover material. If desired, a pouch cover material 22may include a coating of a barrier material to minimize staining of thepouch material by its contents. Preferred characteristics of thecovering material 22 include controlled permeability and high mouthcomfort. These characteristics are available from non-wovenpolypropylene fabric which is preferred for material 22.

Regardless of the external contour of the pouch 20, the integral and/oroverlapping edge portions define an internal cavity enclosed by thecover material 22 sized to receive a carrier for the flavorant. In oneembodiment (see FIG. 2), the carrier 30 may be a substantially solidmaterial such as a dissolvable film that is contained within the covermaterial 22. The flavorant itself may be a surface treatment of thecarrier 30, a mixture with the material of the carrier, or a combinationof such a mixture and a surface treatment. For such an embodiment, theflavorant itself may be selected from the group consisting of tea, rosehips, honey, royal jelly, fruit extracts, vitamins, coffee, fruits,mint, vegetables, sweeteners, international flavors, ginger, pepperextract, exotic flavors, and ethnic flavors. Other flavors are alsowithin the contemplation of this disclosure, whether natural, synthetic,or a combination of natural and synthetic. Moreover, flavors can becombined as may be desired, e.g., coffee-mint, pomegranate-kiwi. Theflavor or combination of flavors is selected to enhance consumersensorial enjoyment of the product.

The carrier 30 may completely fill the chamber defined by the covermaterial 22. Alternatively, there may be substantial empty volume in thepouch 20 and around the carrier 30.

Preferred materials for the carrier 30 include polymeric matrices, ormaterials with very high viscosity (i.e., having a carmel-like ortaffy-like consistency). If desired, the carrier 30 may comprise one ormore pieces of dried fruit. Generally, however, the flavorant is infusedwithin or inherently part of the carrier to provide a long-lastingflavor experience. The carrier 30 may also be soluble so that itdissolves in saliva over time and passes through the porous coveringmaterial 22 into the oral cavity along with the flavorant.

Another embodiment of the carrier 32 (see FIG. 3) comprises a granularor powder material. Again, the granular or powder material may comprisea polymeric matrix, or substantially solid material where the flavorantis (i) a surface coating, (ii) incorporated in the material particles,or (iii) mixed with the carrier material particles.

Another embodiment of the carrier 34 (see FIG. 4) comprises a pluralityof beads. Each bead 34 may be generally spherical or irregularly shaped.Moreover, each bead 34 may be fabricated (i) from the flavorantmaterial, (ii) from a matrix incorporating the flavorant, (iii) with theflavorant as a surface coating, or (iv) a combination of two or more ofthose features. To increase the time duration of flavor release, one ormore of the beads 34 may be encapsulated is a soluble coating whichimpedes flavor release from some of the beads 34 while other beads areactive in flavor release. Thus, encapsulation of all or some of thebeads 34 promotes flavor release over a substantially extended timeperiod.

As with the carrier 30 of the first embodiment, the flavorant used withthe carriers 32, 34 of this embodiment may be selected from the groupconsisting of tea, rose hips, honey, royal jelly, fruit extracts,vitamins, coffee, fruits, mint, vegetables, ginger, pepper extract,sweeteners, exotic flavors, and ethnic flavors. Other flavors are alsowithin the contemplation of this disclosure, whether natural, synthetic,or a combination of natural and synthetic. Moreover, flavors can becombined as may be desired, e.g., coffee-mint, pomegranate-kiwi. Theflavor or combination of flavors is selected to enhance consumersensorial enjoyment of the product.

It should also be noted that this disclosure contemplates use of thepouch to provide functional benefits in the health and beauty,medicinal, and cosmetic fields. For example, the pouch might be used fororal delivery of medication. In such an application, the medication maybe in addition to a flavorant or may comprise the flavorant.Furthermore, this disclosure contemplates that the pouch 20 may includetwo or more flavorants so that compound flavors may be generated.

From the foregoing, it will be observed that a method of flavor deliveryto an oral cavity results from the fabrication and use of the pouch 20according to this disclosure. As an initial step, a desired flavorant iscombined with a carrier. That combination step may include the mixing oftwo or more flavor compounds together to obtain the desired taste. Theflavor compounds may be naturally occurring, or synthetic, or acombination of both. Where a solid carrier is used, that carrier 30 (seeFIG. 2) may be coated with the flavorant, or fabricated with theflavorant as an internal component. Where a particulate carrier is used,that carrier 32 may also be mixed with a particulate flavorant. Or, theflavorant can be incorporated into the carrier material followed bycomminution to the desired particulate size. Combinations of mixture andincorporation are also acceptable. For beads (see FIG. 4) the beads 34may be fabricated entirely from the flavorant, or may be fabricated as amixture of a carrier and the flavorant. To enhance the duration offlavor release, some or all of the beads 34 or particles 32 may beencapsulated. The encapsulation compound is preferably soluble in salivaso that as the encapsulation coating dissolves, additional flavorant isreleased.

With the flavorant having been combined with a carrier, the carrier isplaced or deposited on a blank 40 (see FIG. 5) which may be circular asshown. The blank 40 is a piece of porous covering material 22 describedmore particularly above. Preferably, the material of the blank 40 issubstantially tasteless and may comprise a membrane.

Next (see FIG. 6), the flavorant and carrier material 42 are depositedon the blank 40 such that the flavorant and carrier material 42 arespaced inwardly away from the perimeter of the blank 40.

Depending on the desired external contour of the finished piece, asecond blank may be placed on top of the first blank 40 and the carriermaterial 42. In the presently preferred arrangement, one part of thefirst blank 40 is folded over the carrier material and the other part ofthe blank 40 so as to define a substantially crescent-shaped article(see FIG. 7). Peripheral edge portions of the blank 40 are then sealedto one another (see FIG. 8). Sealing may be accomplished by applying anedible adhesive, or by bonding peripheral portions of the blank 40together. Such bonding may be a form of mutual sealing 46, e.g., thermalor sonic, if desired. Preferably, the overlapping parts of the blank 40are trimmed along the folded edge so as to provide rounded corners 44,thereby effectively eliminating any sharp corners.

With the carrier thus enclosed in the covering material, the assembly isready for distribution and, ultimately, use. In use, the assembly isplaced in the consumer's mouth or oral cavity. If placed on the tongue,saliva contacts the carrier and flavorant through the covering material22 thus releasing the flavor into the oral cavity. The flavorantstypically stimulate production of additional saliva in the mouth so thatcontinuing saliva contact and flavorant release occurs.

Flavorant release may also result from mastication of the carrierbetween the consumer's teeth. In such a situation, the flavorant releaseis accomplished by occasional chewing of the pouch. Extended-time flavorrelease is then accomplished by occasional chewing to release additionalflavor.

Where the flavorant is in bead form, the flavorant may comprise a liquidcontained in one or more rupturable beads. In use, mastication of thepouch 20 will release flavorant on demand. Alternatively, continuedexposure to saliva may dissolve the beads thereby exposing theflavorant. Furthermore, encapsulated beads provide randomly delayedrelease of flavorant from corresponding beads so that flavor releaseoccurs over a relatively extended duration of time.

The pouch 20 of this disclosure has a distinctive, neat, and attractiveappearance. Moreover, the pouch 20 is sized so as to be self-aligning tothe gum base when inserted into the mouth. Furthermore, the absence oforally irritating corners and edges improves the mouth comfort or feelof the resulting pouch 20.

Where the term “about” is used in this specification as a modifier for aspecific number, that term is intended to include not only the specificnumber but also a tolerance for that number of +/−10%.

The pouch of a flavorant and carrier in a tasteless, porous coveringprovides a new delivery system for flavorants to adults. It will also beapparent to those skilled in the art that numerous modifications,variations, substitutions, and equivalents exist for features of theinvention that do not materially depart from the spirit and scope of theinvention. Accordingly, it is expressly intended that all suchmodifications, variations, substitutions, and equivalents which fallwithin the spirit and scope of the appended claims be embraced thereby.

What is claimed is:
 1. A flavor pouch for oral delivery of one or moreflavorants to the human oral cavity, consisting of: a porous membrane ofa form to be received in the human oral cavity; and a first flavorantprovided in a liquid and contained in a plurality of rupturable beadswhich are enclosed by said porous membrane, and a second flavorantcontained in a plurality of dissolvable beads which are also enclosed bysaid porous membrane, wherein said first flavorant and said secondflavorant are operable to release a flavor through said porous membraneinto the human oral cavity; wherein said porous membrane was initiallyprovided in sheet form, was folded to completely enclose said rupturablebeads containing said first flavorant and said dissolvable secondflavorant beads containing said second flavorant, and the overlappingouter region of said porous membrane having been sealed; and whereinsaid first flavorant is capable of immediate release into the oralcavity on demand if desired by the mastication with rupture of said oneor more rupturable beads, and said second flavorant is capable ofrelease through dissolution with the exposure of flavorant containedtherein over an extended duration of time upon contact with saliva. 2.The flavor pouch of claim 1, wherein the porous membrane comprises aweb.
 3. The flavor pouch of claim 1, wherein the first and/or secondflavorant comprises an artificial sweetener.
 4. The flavor pouch ofclaim 1, wherein the first and/or second flavorant includes a flavorselected from the group consisting of tea, rose hips, honey, royaljelly, fruit extract, coffee, ginger, pepper extract, and mint.
 5. Theflavor pouch of claim 1, wherein the major dimension of each flavorpouch is about 0.6 to 1.2 inches.
 6. The flavor pouch of claim 1,wherein the porous membrane is not soluble in saliva and has structuralintegrity sufficient to remain intact while the flavor pouch is presentin a human oral cavity.
 7. The flavor pouch of claim 1, wherein theporous membrane includes combination of natural and synthetic material.8. The flavor pouch of claim 1, wherein the porous membrane is anon-woven web.
 9. The flavor pouch of claim 1, wherein the porousmembrane is sealed only along said overlapping out regions of saidporous membrane.
 10. The flavor pouch of claim 1, wherein the porousmembrane has a basis weight of 5 to 25 g/m².
 11. The flavor pouch ofclaim 1, wherein the porous membrane is a water-permeable,water-insoluble stain resistant polymer membrane.
 12. The flavor pouchof claim 1, wherein the porous membrane includes a coating of a barriermaterial which minimizes staining of the flavor pouch exterior by itscontents.
 13. The flavor pouch of claim 1, wherein said porous membraneis non-woven polypropylene fabric.
 14. The flavor pouch of claim 1,wherein said overlapping out region of said porous membrane having beenheat sealed.
 15. A flavor pouch for oral delivery of one or moreflavorants to the human oral cavity, comprising: a porous membrane ofnon-woven polypropylene fabric; and a first flavorant provided in aliquid and contained in a plurality of rupturable beads which areenclosed by the porous membrane of non-woven polypropylene fabric and asecond flavorant contained in a plurality of dissolvable beads which arealso enclosed by said porous membrane of non-woven polypropylene fabricwherein said first flavorant and second flavorant are operable torelease a flavor through said porous membrane into the human oralcavity, wherein said porous membrane is not soluble in saliva and hasstructural integrity sufficient to remain intact while the flavor pouchis used in a human oral cavity, wherein said porous membrane wasinitially provided in sheet form, was folded to completely enclose saidflavorant beads of said first and second flavorants, and an overlappingouter region of said porous membrane having been sealed, and whereinsaid first flavorant is capable of immediate release into the oralcavity on demand if desired by the mastication with rupture of said oneor more rupturable beads, and said second flavorant is capable ofrelease through dissolution and exposure of flavorant over an extendedperiod of time upon contact with saliva.
 16. The flavor pouch of claim14, wherein the said porous membrane includes a coating of a barriermaterial which minimizes staining of the flavor pouch exterior by itscontents.
 17. The flavor pouch of claim 14, wherein said overlappingouter region of said porous membrane having been heat sealed.